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<p>This study presents the development of a novel sodium anode filament for Fused Filament Fabrication (FFF). The filament formulation utilized Polylactic Acid (PLA) as the polymer matrix and Hard Carbon as the active material, with enhancements from Poly(ethylene glycol) dimethyl ether (PEGDME) and Carbon Black Super-P to improve plasticity and conductivity. The optimal composition was determined using a mixture design approach within the Design of Experiments (DoE) framework. An initial anode slurry was prepared and tested for capacity based on the DoE matrix. Homogeneity and elemental distribution were analyzed using Scanning Electron Microscopy (SEM) and Raman spectroscopy. Rheological analysis showed elastic and viscous modulus values similar to conventional PLA filaments, while frequency sweep tests confirmed shear-thinning behavior, advantageous for extrusion and 3D printing. Mechanical testing revealed a significant reduction in tensile strength and Young’s modulus for the printed anode samples compared to PLA. Electrochemical testing showed that 3D-printed samples exhibited a 5% lower capacity (260 mAh/g) than slurry-coated films (273 mAh/g). Cyclic voltammetry indicated reduced electrochemical activity, attributed to PLA encapsulating active carbon particles, which reduced their accessibility and porosity, hindering electrolyte infiltration and ion diffusion. These findings highlight the potential and challenges of using 3D-printed anode filaments for sodium-ion battery (SIB) storage applications.</p>

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Development and characterization of anode filaments for fused filament fabrication of sodium-ion batteries

  • 期刊论文

  • 发表日期：

    2025年7月5日

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  • M Rahul,
  • P. P. Date,
  • Masoud Jabbari,
  • V. V. N. Phani Kumar,
  • R. Prakash

摘要

This study presents the development of a novel sodium anode filament for Fused Filament Fabrication (FFF). The filament formulation utilized Polylactic Acid (PLA) as the polymer matrix and Hard Carbon as the active material, with enhancements from Poly(ethylene glycol) dimethyl ether (PEGDME) and Carbon Black Super-P to improve plasticity and conductivity. The optimal composition was determined using a mixture design approach within the Design of Experiments (DoE) framework. An initial anode slurry was prepared and tested for capacity based on the DoE matrix. Homogeneity and elemental distribution were analyzed using Scanning Electron Microscopy (SEM) and Raman spectroscopy. Rheological analysis showed elastic and viscous modulus values similar to conventional PLA filaments, while frequency sweep tests confirmed shear-thinning behavior, advantageous for extrusion and 3D printing. Mechanical testing revealed a significant reduction in tensile strength and Young’s modulus for the printed anode samples compared to PLA. Electrochemical testing showed that 3D-printed samples exhibited a 5% lower capacity (260 mAh/g) than slurry-coated films (273 mAh/g). Cyclic voltammetry indicated reduced electrochemical activity, attributed to PLA encapsulating active carbon particles, which reduced their accessibility and porosity, hindering electrolyte infiltration and ion diffusion. These findings highlight the potential and challenges of using 3D-printed anode filaments for sodium-ion battery (SIB) storage applications.